Manual Transmission Reassembly

Manual Transmission Reassembly

NOTE: Prior to reassembly, clean all the parts in solvent, dry them, and apply MTF to any contact surfaces.

1. Install the magnet (A) and differential assembly (B).

NOTE: Clean the magnet any time the transmission is disassembled.






2. Install the 8 mm spring washer (A) and the 8 mm special bolt (B).





3. Install the 36 mm spring washer (C) and the 26 mm washer (D) over the ball bearing (E). Note the installation direction of the spring washer.

4. Tape the mainshaft splines (F) with vinyl tape to protect the seal. Install the mainshaft and the countershaft (G) into the shift forks (H), and install them as an assembly.

5. Install the reverse lock cam.






6. Install the reverse shift fork.






7. Install the reverse idler gear (A) and the reverse gear shaft (B).






8. Select the proper size 72 mm shim (A) according to the measurements made during the Mainshaft Thrust Clearance Adjustment M/T Main shaft Thrust Clearance Adjustment. Install the oil gutter plate (B), oil guide plate M, and the 72 mm shim into the transmission housing (C).





9. Clean any dirt or oil from the transmission housing sealing surface.

10. Apply liquid gasket (P/N 08717-0004, 08718-0001, 08718-0003, or 08718-0009) evenly to the clutch housing mating surface of the transmission housing. Install the component within 5 minutes of applying the liquid gasket.

NOTE:

- If you use liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.
- If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.





11. Install the two 14 x 20 mm dowel pins (A).





12. Make sure the finger (B) of the tapered cone ring contacts the 5th shift fork (C) as shown.

13. Lower the transmission housing the rest of the way as you expand the 52 mm snap ring (D). Release the snap ring so it seats in the groove of the countershaft bearing.

14. Make sure that the 52 mm snap ring is securely seated in the groove of the countershaft bearing.





15. Apply liquid gasket (P/N 08717-0004, 08718-0001, 08718-0003, 08718-0009, or 08718-0012) to the threads of the 32 mm sealing screw (E), and install it on the transmission housing.

16. Install the transmission hanger (A) and the 8 mm flange bolts finger-tight.






17. Torque the 8 mm flange bolts in a crisscross pattern in several steps.









18. Clean any dirt or oil from the change lever assembly sealing surface.

19. Apply liquid gasket (P/N 08717-0004, 08718-0001, 08718-0003, or 08718-0009) evenly to the transmission housing mating surface of the change lever assembly. Install the component within 5 minutes of applying the liquid gasket.

NOTE:

- If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.
- If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.





20. Install the 8 x 10 mm dowel pins (A) and the change lever assembly (B).






21. Install the detent bolts (A), the new 12 mm washers (B), the detent ball springs (C), and the steel balls (D).





22. Install the new washer (E) and the back-up light switch (F).

23. Install the new washers (A), the drain plug (B), the filler plug (C), a new O-ring (D), and the output shaft (countershaft) speed sensor (E).